background image

19

cycled off, the fault code will be cleared on the next power--up but
the fault will remain and system operation will not be as expected.

This is because on power--up, the unit control cannot discern the

difference between an open sensor or if a sensor is not installed.
Step 2—Sequence of Operation

The 577D packaged unit is designed for installation with a

communicating UI. This unit will not respond to commands

provided by a common thermostat except under certain emergency
situations described in Step 1—Start--Up and Troubleshooting.
The UI uses temperature, humidity and other data supplied from
indoor and outdoor system components to control heating or

cooling system for optimum comfort. The unit will be commanded

by UI to supply airflow. The unit will operate the indoor blower at
requested airflow for most modes.
INDOOR AIRFLOW ADJUSTMENTS
The nominal requested airflow for air conditioner operations will be

350 cfm per ton of nominal cooling capacity as defined by unit size.
Actual airflow request will be adjusted from nominal using indoor

and outdoor temperature and indoor humidity data to optimize the

system operation for occupant comfort and system efficiency. Refer
to UI literature for further system control details.

UNIT OPERATION HAZARD

Failure to follow this caution may result in unit damage.
For cooling operation, the recommended airflow is 350 to 450

cfm for each 12,000 Btuh of rated cooling capacity. For

heating operation, the airflow must produce a temperature rise

that falls within the range stamped on the unit rating plate.

CAUTION

!

For gas heat operations, Table 4 shows the temperature rise in each
gas heating mode. Refer to these tables to determine the desired

heating airflow for the system being installed.

NOTE

: Be sure that all supply--and return--air grilles are open, free

from obstructions, and adjusted properly.Airflow can be changed
using the UI. See UI installation instructions for more detail.

NOTE

: Once the compressor has started and then has stopped, it

should not be started again until 4 minutes have elapsed. The
cooling cycle remains “on” until the room temperature drops to
point that is slightly below the cooling control setting of the UI.

AIR CONDITIONER SEQUENCE OF OPERATION
COOLING OPERATION
With a call for first stage cooling, the outdoor fan, and low stage
compressor are energized. If low--stage cannot satisfy cooling

demand, high--stage cooling is energized by the UI. After second
stage is satisfied, the unit returns to low--stage operation until first

stage is satisfied or until second stage is required again. When both
first stage and second stage cooling are satisfied, the compressor will

shut off.

NOTE

: When two--stage unit is operating at low--stage, system

vapor (suction) pressure will be higher than a standard
single--stage system or high--stage operation.

NOTE

: Outdoor fan motor will continue to operate for one

minute after compressor shuts off, when outdoor ambient is
greater than or equal to 100

°

F.

UTILITY INTERFACE WITH Evolution CONTROL
The utility curtailment relay should be connected to factory

supplied pigtails (PINK, connected to R, VIOLET connected to
Y2 on the control board) located in the low voltage splice box

(See Fig. 13, 14 and 16). This input allows a power utility device

to interrupt compressor operation during peak load periods.
When the utility sends a signal to shut the system down, the UI

will display “Curtailment Active”.
COMPRESSOR OPERATION
When the compressor is operating in low stage, the modulating

ring is deactivated, allowing two internal bypass ports to close off

33% of the scroll compression area so the system operates at part
load capacity. The 24--volt solenoid coil is de--energized in

low--stage operation.
When the compressor is operating at high stage, the modulating

ring is activated, sealing the bypass ports, which allows the

compressor to operate at full load capacity. The 24--volt solenoid
coil is energized in high stage operation.
CRANKCASE HEATER OPERATION (IF APPLICABLE)
The crankcase heater is energized during off cycle below 65

_

F

outdoor air temperature.
OUTDOOR FAN MOTOR OPERATION
The outdoor unit control energizes the outdoor fan any time the

compressor is operating. The outdoor fan remains energized if a
pressure switch or compressor overload should open. Outdoor fan

motor will continue to operate for one minute after the
compressor shuts off when the outdoor ambient is greater than or

equal to 100

_

F.

TIME DELAYS--AIR CONDITIONER OPERATIONS
The unit time delays include:

S

Five minute time delay to start cooling operation when
there is a call from the thermostat or user interface. To
bypass this feature, momentarily short and release

Forced Defrost pins.

Table 4—

Air Delivery and Temperature Rise at Rated Heating Input

Rated Heating Input (Btu/hr)

Heating Rise Range (

o

F)

Heating Rise (Either Stage,

°

F)

Unit

High Stage

Low Stage

High Stage

Low Stage

“Efficiency”

“Comfort”

High Stage

Low Stage

High Stage

Low Stage

High Stage

Low Stage High Stage Low Stage

577D024040

40 000

26 000

20 50

15 45

35

30

40

35

577D024040

577D030040

40,000

26,000

20 -- 50

15--45

35

30

40

35

577D030060

577D030060

577D036060

60 000

39 000

25 55

25 55

40

50

577D036060

577D042060

60,000

39,000

25 -- 55

25 -- 55

40

50

577D042060
577D036090

577D036090

577D042090

90 000

58 500

35 65

35 65

50

55

577D042090

577D048090

90,000

58,500

35 -- 65

35 -- 65

50

55

5

0 8090

577D060090
577D048115

115 000

75 000

30 60

30 60

45

50

577D048115

577D060115

115,000

75,000

30 -- 60

30 -- 60

45

50

577D048130

130 000

84 500

35 65

35 65

50

55

577D048130

577D060130

130,000

84,500

35 -- 65

35 -- 65

50

55

Airflow delivery values for external static pressure values of up to 1” wc.

577D

Summary of Contents for EVOLUTION 577D

Page 1: ...and Heating Control Operation 25 Checking and Adjusting Refrigerant Charge 25 Refrigerant Charge 25 No Charge 25 Low Charge Cooling 25 To Use Cooling Charging Charts 25 Non Communicating Emergency Cooling Heating Mode 25 MAINTENANCE 27 29 Air Filter 27 Indoor Fan and Motor 27 Inducer Blower 27 Limit Switch 27 A06047 Fig 1 Unit 577D Burner Ignition 27 Main Burners 27 Inducer Pressure Switch 27 Outd...

Page 2: ...w NOx units designed for California installations These models meet the California maximum oxides of nitrogen NOx emissions requirements of 40 nanograms joule or less as shipped from the factory and must be installed in California Air Quality Management Districts or any other regions in North America where a Low NOx rule exists NOTE Low NOx requirements apply only to natural gas installations RECE...

Page 3: ...t CTyp G E F G D E A05308 UNIT SIZE ODS CATALOG NUMBER A IN MM B IN MM C IN MM D IN MM E IN MM F IN MM G IN MM 024 030 CPRFCURB006A00 8 203 11 279 16 1 2 419 28 3 4 730 30 3 8 771 44 5 16 1126 45 15 16 1167 024 030 CPRFCURB007A00 14 356 11 279 16 1 2 419 28 3 4 730 30 3 8 771 44 5 16 1126 45 15 16 1167 036 060 CPRFCURB008A00 8 203 16 3 16 411 17 3 8 441 40 1 4 1022 41 15 16 1065 44 7 16 1129 46 1 ...

Page 4: ...4 A06604 Fig 5 577D024 030 Unit Dimensions ...

Page 5: ...5 A06605 Fig 6 577D036 060 Unit Dimensions ...

Page 6: ...sq ft 3 17 3 7 3 17 3 7 3 17 3 7 3 17 3 7 3 17 4 7 3 17 4 7 3 17 4 7 3 17 4 7 INDOOR FAN Nominal Airflow Cfm Comfort Variable based on Comfort Roll back see User Interface instructions for more information Efficiency 700 700 875 875 1050 1050 1225 1225 Max 800 800 1000 1000 1200 1200 1400 1400 Furnace gas ht airflow Low Stage 475 727 475 727 745 875 745 875 Furnace gas ht airflow High Stage 844 11...

Page 7: ...velocity of 300 ft minute for throwaway type or 450 ft minute for high capacity type Air filter pressure drop for non standard filters must not exceed 0 08 in wg Step 3 Provide Clearances The required minimum service clearances are shown in Fig 5 and 6 Adequate ventilation and outdoor air must be provided The outdoor fan draws air through the outdoor coil and discharges it through the top fan gril...

Page 8: ...t strip screws when re securing the unit If a screw is stripped replace the stripped one with a larger diameter screw included WARNING Rigging Lifting of Unit 1 Bend top of brackets down approximately 30 degrees from the corner posts 2 Attach straps of equal length to the rigging brackets at opposite ends of the unit Be sure straps are rated to hold the weight of the unit See Fig 7 3 Attach a clev...

Page 9: ...ow latest Sheet Metal and Air Conditioning Contractors National Association SMACNA and Air Conditioning Contractors Association ACCA minimum installation standards for residential heating and air conditioning systems 5 Secure all ducts to building structure Flash weatherproof and vibration isolate duct openings in wall or roof according to good construction practices CONVERTING HORIZONTAL DISCHARG...

Page 10: ...13 Fig 9 Condensate Trap Step 8 Install Gas Piping The gas supply pipe enters the unit through the access hole provided The gas connection to the unit is made to the 1 2 in FPT gas inlet on the gas valve Install a gas supply line that runs to the heating section Refer to Table 2 and the current edition of NFGC in the U S and the current NSCNGPIC in Canada Do not use cast iron pipe It is recommende...

Page 11: ...nector Do not use a connector which has previously serviced another gas appliance WARNING 8 Check for gas leaks at the field installed and factory installed gas lines after all piping connections have been completed Use soap and water solution or method specified by local codes and or regulations Step 9 Install Electrical Connections ELECTRICAL SHOCK HAZARD Failure to follow this warning could res...

Page 12: ...O HUMIDITY CONTROL COMFORT ROLLBACK ETC WILL BE LOST IF THE OAT IS NOT CONNECTED For detailed mounting instructions for the OAT sensor please refer to TSTATXXSEN01 B installation instructions catalog no 63TS TA13 Procedures 1 through 3 The OAT input is used to supply outdoor temperature data for systemlevel functionsand fortemperature displayon UserInterface UI Using two wires of the field supplie...

Page 13: ...L BLK GROUND LEAD SINGLE PHASE CONNECTIONS TO DISCONNECT PER NEC LEGEND NEC National Electrical Code Field Wiring Splice Connections NOTE Use copper wire only L1 L2 A06299 Fig 12 Line Power Connections A06306 Fig 13 Control Plate 577D ...

Page 14: ...t shall be Power Supply fuse The CGA Canadian Gas Association units may be fuse or circuit breaker 2 Minimum wire size is based on 60 C copper wire I fother than 60 C wire is used or if length exceeds wire length in table determine size from NEC 3 Unbalanced 3 Phase Supply Voltage Never operate a motor where a phase imbalance in supply volt age is greater than 2 Use the following formula to determ...

Page 15: ...is correctly positioned in fan orifice Top 1 3 of condenser fan blade should be within fan orifice venturi c Ensure fan hub is positioned correctly with respect to motor housing See Fig 23 d Make sure that air filter s is in place e Make sure that condensate drain trap is filled with water to ensure proper drainage f Make sure that all tools and miscellaneous loose parts have been removed 5 Compre...

Page 16: ... alone can be replaced MOTOR TURNS SLOWLY 1 Low static pressure loading of blower while access panel is removed will cause blower to run slowly Particularly at low airflow requests This is normal do not assume a fault exists 2 Recheck airflow and system static pressure using UI service screens with access panel in place NOTE Blower motor faults will not cause a lockout of blower operation The fan ...

Page 17: ...17 6 0 A06310 Fig 16 Wiring Schematic 577D Single Phase 577D ...

Page 18: ... system defective switch or connections or inadequate combustion air supply flame roll out switch open STATUS CODE 34 IGNITION PROVING FAILURE Control will try three more times before lockout 14 occurs If flame signal lost during blower on delay period blower will come on for the selected blower off delay Check for oxide buildup on flame sensor clean with fine steel wool proper flame sense microam...

Page 19: ...r suction pressure will be higher than a standard single stage system or high stage operation NOTE Outdoor fan motor will continue to operate for one minute after compressor shuts off when outdoor ambient is greater than or equal to 100 F UTILITY INTERFACE WITH Evolution CONTROL The utility curtailment relay should be connected to factory supplied pigtails PINK connected to R VIOLET connected to Y...

Page 20: ...pears while cooling or heat ing demand exists Possible causes are internal compressor over load trip or start relay not releasing if installed Contactor Shorted 73 Compressor voltage sensed when no demand for compressor op eration exists Contactor may be stuck closed or there is a wiring error No 230V at Compressor 74 Compressor voltage not sensed when compressor should be start ing Contactor may ...

Page 21: ...at the ignition control will changetheinducerspeedtolow speedand keepthe gasvalve energized on low stage If the UI is asking for high stage gas heat the ignition control will maintain running the inducer on high speed and energize the gas valve s high stage relay to increase gas flow If the burner flame is not proved within 2 seconds the control will close the gas valve and repeat the ignition seq...

Page 22: ...W PLASTIC ADJUST SCREW LOW STAGE GAS PRESSURE REGULATOR ADJUSTMENT MANIFOLD PRESSURE TAP INLET PRESSURE TAP ON OFF SWITCH REGULATOR SPRING HIGH STAGE GAS PRESSURE REGULATOR ADJUSTMENT A04167 Fig 18 Redundant Automatic Gas Control Valve NOTE DO NOT set low stage manifold pressure less than 1 4 in wc or more than 2 0 in wc for natural gas If manifold pressure is outside this range change main burner...

Page 23: ...t one revolution takes 84 sec and the heating value of the gas is 1050 Btu ft3 Proceed as follows a 84 sec to complete one revolution b 3600 84 42 9 c 42 9 x 2 85 8 ft3 of gas flow hr d 85 8 x 1050 90 090 Btuh input In this example the nominal input rate for high stage is 90 000 Btu hr so the high stage manifold pressure is correctly set If the measured high stage rate is too low increase the mani...

Page 24: ...lem in the case of a gas component failure To initiate the component test procedure ensure that there arenoUIinputstothecontrol theABCDconnectorcan beremoved from the Evolution control board for this operation and all time delays have expired Turn on setup switch SW1 6 NOTE The component test feature will not operate if the control is receiving any UI signals or until all time delays have expired ...

Page 25: ...affect the reading Indoor air CFM must be within the normal operating range of the unit TO USE COOLING CHARGING CHARTS Take the liquid line temperature and read the manifold pressure gauges Refer to the chart to determine what the liquid line temperature should be NOTE If the problem causing the inaccurate readings is a refrigerant leak refer to Check for Refrigerant Leaks section NON COMMUNICATIN...

Page 26: ...02 97 87 2578 41 39 36 30 384 108 103 98 88 2647 42 40 37 31 394 110 105 100 90 2716 44 41 38 32 404 112 107 102 92 2785 45 42 39 33 414 114 109 104 94 2854 46 43 40 34 424 116 111 106 96 2923 47 44 41 35 434 118 113 108 98 2992 48 45 42 36 444 119 114 109 99 3061 48 46 43 37 454 121 116 111 101 3130 49 47 44 38 464 123 118 113 103 3199 50 48 45 39 474 124 119 114 104 3268 51 48 46 40 484 126 121 ...

Page 27: ...mensional size and type as originally installed See Table 1 for recommended filter sizes Inspect air filter s at least once each month and replace throwaway type or clean cleanable type at least twice during each cooling season and twice during the heating season or whenever the filter becomes clogged with dust and lint Step 2 Indoor Fan and Motor NOTE All motors are pre lubricated Do not attempt ...

Page 28: ...and securely After inspecting the electrical controls and wiring replace all the panels Start the unit and observe at least one complete cooling cycle to ensure proper operation If discrepancies are observed in operating cycle or if a suspected malfunction has occurred check each electrical component with the proper electrical instrumentation Refer to the unit wiring label when making these checks...

Page 29: ... performing any service that may risk exposure ofcompressor oil to the roof take appropriate precautions to protect roofing Procedures which risk oil leakage include but are not limited to compressor replacement repairing refrigerant leaks and replacing refrigerant components such as filter drier pressure switch metering device coil accumulator or reversing valve Synthetic Roof Precautionary Proce...

Page 30: ...emand for compressor operation the contactor may be stuck closed or there is a wiring error The control will flash the appropriate fault code COMPRESSOR THERMAL CUTOUT If the control senses the compressor voltage after start up and is then absent for 10 consecutive seconds while cooling demand exists the thermal protector is open The control de energizes the compressor contactor for 15 minutes but...

Page 31: ...r should fail low ambient cooling will not be allowed Defrost will occur at each time interval during heating operation but will terminate after 5 minutes If there is a thermistor out of range error defrost will occur at each time interval during heating operation but will terminate after 5 minutes Refer to the Troubleshooting Chart Table 10 for additional troubleshooting information A06311 Fig 25...

Page 32: ...th 520 psig low side retard S Use hoses with 750 psig service pressure rating S Leak detectors should be designed to detect HFC refrigerant S Puron as with other HFCs is only compatible with POE oils S Vacuum pumps will not remove moisture from oil S Only use factory specified liquid line filter driers with rated working pressures no less than 600 psig S Do not install a suction line filter drier ...

Page 33: ... capacitor Replace Restriction in refrigerant system Locate restriction and remove Dirty air filter Replace filter Unit undersized for load Decrease load or increase unit size UI temperature set too low Reset UI setting Compressor operates continuously Low refrigerant charge Locate leak repair and recharge Co p esso ope ates co t uous y Air in system Recover refrigerant evacuate system and re char...

Page 34: ...ight unit 2 Check gas valve Inducer pressure switch not closing 1 Check pressure switch wires connections and tubing Repair or replace if necessary Dirty air filter Clean or replace filter as necessary Gas input to unit too low Check gas pressure at manifold match with that on unit nameplate Inadequate heating Unit undersized for application Replace with proper unit or add additional unit Inadequa...

Page 35: ...35 577D ...

Page 36: ..._ INDOOR EVAPORATOR FAN AMPS___________ TEMPERATURES OUTDOOR CONDENSER AIR TEMPERATURE ___________DB RETURN AIR TEMPERATURE ___________DB ___________WB COOLING SUPPLY AIR ___________DB ___________WB GAS HEAT SUPPLY AIR ___________ PRESSURES REFRIGERANT SUCTION ___________PSIG SUCTION LINE TEMP ___________ REFRIGERANT DISCHARGE ___________PSIG DISCHARGE TEMP ___________ VERIFY REFRIGERANT CHARGE US...

Reviews: